Project Manager

Contract position based in Charlotte, NC.

Responsibilities

• Own the delivery of manufacturing automation across heat exchanger and final assembly processes for water-cooled (shell and tube) and air-cooled (finned tube coil) HVAC products.
• Design and implement automation for water-cooled heat exchangers, including tube bundle handling, tube-to-tube sheet joining via expansion and/or seal welding, shell and nozzle welding, and automated pressure and leak test systems.
• Develop and deploy automation for air-cooled finned tube coils, including tube insertion and expansion, header and manifold joining through brazing, automated coil leak and pressure testing, and coil handling and fixturing solutions.
• Implement flexible automation and assist systems for heavy final assembly operations, including refrigerant charging systems, piping, brazing and welding support, sensor installation, control integration, and end-of-line test automation and reporting.
• Own or support the design, configuration, and maintenance of PLC, HMI, and safety logic for manufacturing automation systems, using platforms such as Rockwell and Siemens.
• Drive reliability improvements in automation systems through enhanced diagnostics, alarm rationalization, and robust fault recovery strategies.
• Build and expand automated test capabilities, including pressure, leak, and functional testing, using recipe-based execution and structured data capture, with LabVIEW as a typical test automation platform.
• Enable or improve product and process traceability and test data capture through manufacturing execution system (MES) interfaces or structured data collection systems.
• Identify and quantify hard savings opportunities tied to automation, including labor reduction, scrap and rework reduction, downtime reduction and uptime gains, yield and first-pass yield improvement, warranty and field failure reduction, and energy and consumables savings.
• Develop clear automation investment cases and capital expenditure requests that document baseline losses and constraints, proposed solution options, financial metrics such as payback period and NPV/IRR when applicable, sensitivity analysis, and detailed implementation costs.
• Prioritize a pipeline of automation projects with a focus on fast payback, scalable solutions that can be replicated across production lines and product families.
• Own benefits realization by creating savings tracking plans with Finance, validating savings at 30, 60, and 90 days and on a quarterly basis, and putting controls in place to sustain savings through standard work, training, and audits.
• Lead suppliers and system integrators end to end, including requirements definition, RFQ issuance, technical evaluation, acceptance criteria development, factory and site acceptance testing, commissioning, ramp-up, and handoff to operations.
• Define and enforce run-at-rate metrics and require demonstrable performance in cycle time, uptime, and quality from vendors and integrators.
• Ensure long-term maintainability of automation systems by driving thorough documentation, code management practices, spare parts strategies, preventive maintenance plans, and training packages for maintenance and operations teams.
• Embed safety and compliance requirements into automation design and commissioning activities, including risk assessments, guarding, interlocks, lockout/tagout readiness, and safety validation.
• Partner with New Product Introduction, Manufacturing Engineering, and Quality teams to maintain PFMEAs, control plans, reaction plans, and capability checks for automated processes.
• Drive defect reduction and escape prevention in welding, brazing, and leak test operations through robust process controls and continuous improvement.
• Lead continuous improvement initiatives using data-based root cause analysis tools such as 8D, 5 Why, and Fishbone diagrams, along with Lean methodologies.
• Develop and standardize automation design practices, including preferred sensor types, safety architectures, HMI conventions, and test data formats.
• Reduce reliance on tribal knowledge by building repeatable processes, standard operating procedures, and troubleshooting playbooks for automation systems.
• Oversee and lead manufacturing automation delivery from design through commissioning and sustaining, ensuring that systems perform reliably in live factory environments.
• Oversee and lead controls and test system troubleshooting for PLC, HMI, and safety systems by understanding control processes and guiding PLC technicians who perform hands-on work.
• Perform cost modeling and ROI-based prioritization of automation projects to ensure capital is deployed effectively.
• Lead savings identification and validation activities with Finance, maintaining a disciplined focus on verified hard savings.
• Provide technical leadership to vendors and integrators, ensuring alignment with technical requirements, safety standards, and performance expectations.
• Apply a strong safety culture and compliance mindset to all aspects of automation design, implementation, and operation.
• Travel extensively to vendor sites, international manufacturing locations, and greenfield sites to support automation deployment, commissioning, and ramp-up activities.

Requirements

• Bachelor’s degree.
• 10+ years of experience delivering manufacturing automation in production environments.
• 8+ years of experience building business cases and delivering verified savings in areas such as labor, scrap, uptime, and first-pass yield.
• 8+ years of experience commissioning and sustaining automation systems in live factory settings.
• Proven ability to translate manufacturing problems into measurable improvement initiatives.
• Demonstrated experience overseeing and leading manufacturing automation delivery from design through commissioning and sustainment.
• Experience overseeing and leading controls and test system troubleshooting, including PLC, HMI, and safety logic, with the ability to understand control processes while working with PLC technicians who perform hands-on programming.
• Proficiency in cost modeling and ROI-based prioritization of automation projects.
• Experience in savings identification and validation in collaboration with Finance, with a strong discipline around hard savings.
• Demonstrated vendor and integrator technical leadership, including managing requirements, evaluations, and acceptance testing.
• Strong data-driven problem-solving skills using structured methodologies.
• Demonstrated commitment to a strong safety culture and compliance mindset in manufacturing environments.
• Ability and willingness to travel extensively as projects advance, including international and domestic travel.
• Experience in manufacturing process automation, including automation leadership, commissioning, vendor management, and sustaining activities.
• Experience with welding automation and leak and pressure testing automation in manufacturing environments.
• Experience with control panel automation and related processes.
• Strong communication, leadership, and organizational skills.
• Experience with HVAC-related manufacturing processes or products.

Qualifications

• Bachelor’s degree in Mechanical, Electrical, Mechatronics, Manufacturing, or Industrial Engineering, or equivalent experience; a Master’s degree is a plus.
• Experience with heat exchanger manufacturing, including shell and tube and/or finned tube coil designs.
• Experience with commercial HVAC chiller assembly, including water-cooled and air-cooled units.
• Hands-on experience with automated welding and brazing processes in production environments.
• Experience with automated leak and pressure testing systems.
• Familiarity with MES systems, traceability solutions, test data acquisition systems, and industrial networking.

Pay

$60.00 - $70.00/hr.

Benefits

• Medical, dental & vision
• Critical Illness, Accident, and Hospital insurance
• 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available
• Life Insurance (Voluntary Life & AD&D for the employee and dependents)
• Short and long-term disability
• Health Spending Account (HSA)
• Transportation benefits
• Employee Assistance Program
• Time Off/Leave (PTO, Vacation or Sick Leave)

Schedule

Fully onsite position in Charlotte, NC.